INSTALLATION AND SERVICE INSTRUCTIONS

Transcription

1 INSTALLATION AND SERVICE INSTRUCTIONS FREE COOLING UNIT SYSTEM WALL-MOUNTED PACKAGE AIR CONDITIONER(S) & BARD-LINK PLC LEAD/LAG CONTROLLER AIR CONDITIONER MODELS W48A2PQ W60A2PQ W72A2PQ W48L2PQ W60L2PQ W72L2PQ CONTROLLER MODEL LC NOTE: BARD-LINK LC Controller is required for operation when multiple W***2PQ units are used. Bard Manufacturing Company, Inc. Bryan, Ohio Manual : Supersedes: NEW Date: Page 1 of 82

2 CONTENTS SECTION 1: Installation Instructions... 7 List of Necessary Materials/Tools...8 Site Preparation...9 Wall-Mount Unit Installation...11 Wall-Mount Unit Supply Wiring...15 Preliminary Start-Up...18 Bard-Link TM Controller Installation...19 System Start-Up...31 SECTION 2: Service Instructions General Refrigerant Information...36 Sequence of Operation...38 Advanced Programming...43 Using the TEC-EYE...48 Componentry Specifications...52 Maintenance and Troubleshooting...57 SECTION 3: Appendix Appendix: LC-Series Controller and TEC-EYE Architecture...64 FIGURES AND TABLES Figure 1.1 W-Series Model Nomenclature...8 Figure 1.2 Dimensions...10 Figure 1.3 Mounting Instructions...12 Figure 1.4 Electric Heat Clearance...13 Figure 1.5 Wall Mounting Instructions...13 Figure 1.6 Wall Mounting Instructions...14 Figure 1.7 Common Wall Mounting Installations...14 Figure 1.8 Circuit Routing Label...16 Figure 1.9 WIRING: VAC Supply Wiring Landing Points...16 Figure 1.10 Adjusting the VAC Transformer...17 Figure 1.11 WIRING: Typical LC5000 Wiring...19 Figure 1.12 Remote Indoor Sensor Installation...21 Figure 1.13 Additional Remote Sensor Installation...22 Figure 1.14 Power and Signal Connections Smoke...23 Figure 1.15 WIRING: Communication Wiring...24 Figure 1.16 WIRING: Communication Wiring: Controller Termination...25 Figure 1.17 WIRING: Communication Wiring: 1st Unit Termination...26 Figure 1.18 WIRING: Communication Wiring: Additional Unit Termination...27 Figure 1.19 Controller Circuit Install...28 Figure 1.20 Controller Grounding Posts...28 Figure 1.21 WIRING: LC5000 Wiring Diagram...30 Figure 1.22 Clock/Scheduler Menu...31 Figure 1.23 Total Units Displayed...31 Figure 1.24 Bard-Link TM Controller and TEC-EYE...32 Figure 1.25 Status Display Showing Units "Online"...33 Figure 1.26 Status Display Showing Units "Offline"...33 Figure 1.27 Board Switch Display...33 Figure 1.28 Executing Run Test...34 Figure 2.1 Refrigerant Sight Glass...37 Figure 2.2 Wall-Mount Unit Control Board...39 Figure 2.3 Controller Board and Terminal Block...41 Figure 2.4 LC Controller Control Board...41 Figure 2.5 Free Cooling Damper Operation...42 Figure 2.6 Bard-Link TM Controller Display...43 Figure 2.7 Controller Status Display...44 Figure 2.8 Total Units Displayed...44 Figure 2.9 Status Display Showing Units "Online"...45 Figure 2.10 Status Display Showing Units "Offline"...45 Figure 2.11 Board Switch Display...45 Figure 2.12 Executing Run Test...45 Figure 2.13 TEC-EYE Display...48 Figure 2.14 TEC-EYE Connection to Unit Control...48 Figure 2.15 TEC-EYE Status Display...49 Figure 2.16 Local and Current Cool/Heat Setpoints...49 Figure 2.17 Executing Run Test...50 Figure 2.18 Fan Blade Setting...54 Figure 2.19 Dirty Filter Switch and Airflow Switch...54 Figure 2.20 High Pressure Relay Circuit...54 Figure 2.21 Unit Control Panel...55 Figure 2.22 WIRING: Unit Wiring Diagram...56 Table 1.1 Electrical Specifications...15 Table 1.2 Terminal Block Index...29 Table 1.3 Controller Default Settings...34 Table 2.1 Nominal Pressures...37 Table 2.2 Controller Default Settings...42 Table 2.3 Controller Programmable Features...47 Table 2.4 Temp vs. Resistance of Temp Sensor...52 Table 2.5 Indoor Blower Performance...54 Page 2 of 82

3 GENERAL INFORMATION FREE COOLING UNIT SYSTEM The Bard Free Cooling Unit system is composed of wall-mounted air conditioners matched with a Bard-Link TM PLC lead/lag controller or thermostat. The wall mounts are specifically engineered for telecom motor control center rooms. If only one wall-mounted air conditioner is being used, it can be matched with either the Bard-Link TM PLC lead/lag controller or thermostat. If more than one wall mount is installed, the Bard-Link TM PLC lead/lag controller must be matched with the air conditioning units. NOTE: The Bard-Link TM PLC lead/lag controller and wall-mount units are designed specifically to work together. The PLC controller cannot run other Bard models or other brands of systems, nor can other controllers run the PLC wall-mount units. They are a complete system, and must be used together. WALL-MOUNT AIR CONDITIONER UNITS The W-Series units operate on VAC power. The units will supply 100% of rated cooling airflow in free cooling mode with ability to exhaust the same amount through the unit itself without any additional relief openings in the shelter. Each of these units are fully charged with refrigerant and have auxilliary heat installed. BARD-LINK TM PLC CONTROLLER LC (controller and accessories included with controller shown below). LC Series TEC-EYE Hand-Held Diagnostic Tool Bard P/N Programmable Logic Controller Remote Temperature/ Humidity Sensor* Bard P/N Communication EMI Filters Bard P/N * One remote temperature/humidity sensor is included with the LC controller. If the site in which the LC controller will be used has more than one zone (maximum three zones per LC ), additional remote temperature/humidity sensors (one sensor per zone) will need to be purchased and installed in the additional zones. One additional temperature-only sensor may also be used in Zone 1 but will also need to be purchased separately. SINGLE UNIT OPERATION Bard thermostat or can be used in place of the BARD-LINK TM PLC controller when only one W-Series wall mount air conditioner is being installed. If using a thermostat instead of the PLC controller, the alarm logging and remote communication capabilities of the controller will not be available. See page 20 for information on installing and setting up the thermostat for single unit operation. Page 3 of 82

4 The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. The refrigerant system is completely assembled and charged. All internal wiring is complete. The unit is designed for use with or without duct work. Flanges are provided for attaching the supply and return ducts. These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit. These instructions and any instructions packaged with any separate equipment required to make up the entire air conditioning system should be carefully read before beginning the installation. Note particularly Starting Procedure and any tags and/or labels attached to the equipment. While these instructions are intended as a general recommended guide, they do not supersede any national and/or local codes in any way. Authorities having jurisdiction should be consulted before the installation is made. See Additional Publications for information on codes and standards. Sizing of systems for proposed installation should be based on heat loss calculation made according to methods of Air Conditioning Contractors of America (ACCA). The air duct should be installed in accordance with the Standards of the National Fire Protection Association for the Installation of Air Conditioning and Ventilating Systems of Other Than Residence Type, NFPA No. 90A, and Residence Type Warm Air Heating and Air Conditioning Systems, NFPA No. 90B. Where local regulations are at a variance with instructions, installer should adhere to local codes. Shipping Damage Upon receipt of equipment, the cartons should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier s agent. These units must remain in upright position at all times. ADDITIONAL PUBLICATIONS These publications can help when installing the furnace. They can usually be found at the local library or purchased directly from the publisher. Be sure to consult the current edition of each standard. National Electrical Code...ANSI/NFPA 70 Standard for the Installation of Air Conditioning and Ventilating Systems...ANSI/NFPA 90A Standard for Warm Air Heating and Air Conditioning Systems...ANSI/NFPA 90B Load Calculation for Residential Winter and Summer Air Conditioning... ACCA Manual J Duct Design for Residential Winter and Summer Air Conditioning and Equipment Selection... ACCA Manual D For more information, contact these publishers: Air Conditioning Contractors of America (ACCA) 1712 New Hampshire Ave. N.W. Washington, DC Telephone: (202) Fax: (202) American National Standards Institute (ANSI) 11 West Street, 13th Floor New York, NY Telephone: (212) Fax: (212) American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc. (ASHRAE) 1791 Tullie Circle, N.E. Atlanta, GA Telephone: (404) Fax: (404) National Fire Protection Association (NFPA) Batterymarch Park P. O. Box 9101 Quincy, MA Telephone: (800) Fax: (617) Page 4 of 82

5 ANSI Z535.5 Definitions: DANGER: Indicate[s] a hazardous situation which, if not avoided, will result in death or serious injury. The signal word DANGER is to be limited to the most extreme situations. DANGER [signs] should not be used for property damage hazards unless personal injury risk appropriate to these levels is also involved. WARNING: Indicate[s] a hazardous situation which, if not avoided, could result in death or serious injury. WARNING [signs] should not be used for property damage hazards unless personal injury risk appropriate to this level is also involved. CAUTION: Indicate[s] a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION [signs] without a safety alert symbol may be used to alert against unsafe practices that can result in property damage only. NOTICE: [this header is] preferred to address practices not related to personal injury. The safety alert symbol shall not be used with this signal word. As an alternative to NOTICE the word CAUTION without the safety alert symbol may be used to indicate a message not related to personal injury.! WARNING Electrical shock hazard. Have a properly trained individual perform these tasks. Failure to do so could result in electric shock or death.! WARNING Fire hazard. Maintain minimum 1/4" clearance between the supply air duct and combustible materials in the first 3' feet of ducting. Failure to do so could result in fire causing damage, injury or death.! WARNING Heavy item hazard. Use more than one person to handle unit. Failure to do so could result in unit damage or serious injury.! CAUTION Cut hazard. Wear gloves to avoid contact with sharp edges. Failure to do so could result in personal injury. Page 5 of 82

6 Page 6 of 82

7 SECTION 1: INSTALLATION INSTRUCTIONS Page 7 of 82

8 LIST OF NECESSARY MATERIALS/TOOLS Additional hardware and miscellaneous supplies are needed for installation. These items are field supplied and must be sourced before installation. This list also includes tools needed for installation. LIST OF MATERIALS/TOOLS Personal protective equipment/safety devices Supply/return grilles Field-fabricated sleeves (if necessary) 5/16" diameter anchor/carriage/lag bolts 7/8" diameter washers Caulking materials Miscellaneous hand and power tools and jobsite or shop materials Lifting equipment with the necessary capacity and rigging to safely move/install the systems Electrical supplies - Various size circuit breakers for the shelter AC breaker box (see Table 1.1: Electrical Specifications on page 15) - High-voltage wire of various gauges (see Table 1.1) - Communication wire: 2-wire, 18 gauge, shielded with drain - 5-wire, 18 gauge shielded cable with drain for remote temperature and humidity sensor - CAT 6 Ethernet cable of field-determined length (for remote communication, if applicable) - Miscellaneous electrical supplies including rigid/flexible conduit and fittings, junction boxes, wire connectors and supports FIGURE 1.1 W-Series Wall-Mount Unit Model Nomenclature W 72 A 2 P Q 15 5 P X X X D MODEL SERIES CAPACITY 48 4 Ton 60 5 Ton 72 6 Ton A Right Hand L Left Hand REVISION PLC VOLTS & PHASE Q KW KW 3 Stage* * 3 Stage Heat: 6, 9 or 15 KW ECONOMIZER Default Enthalpy, Convert to DB only CONTROL MODULES D Airflow Switch, Dirty Filter Switch, High Pressure Switch, Low Pressure Switch, Compressor Control Module, Low Ambient Control, Evaporator Freeze Protection, Refrigerant Alarm (from PLC) and Compressor Crankcase Heater COIL OPTIONS X Standard 3 Phenolic Coated Evaporator and Condenser for coastal or other severe duty environments SPECIAL FEATURES COLOR OPTIONS X Beige 1 White 4 Buckeye Gray FILTER OPTIONS P 2" Pleated (MERV 8) M 2" Pleated (MERV 11) X 1" Fiberglass (MERV 2) (Standard) Page 8 of 82

9 SITE PREPARATION NEW SHELTER INSTALLATION VS. RETROFIT INSTALLATION These installation instructions cover both new shelter installations and retrofit installations. Each installation is unique and may require special accomodations and modifications. Although Bard Manufacturing follows a long-established tradition of manufacturing equipment using industry standard dimensions for building penetration, it is occasionally necessary to move or enlarge supply and return openings when replacing non-standardized equipment in a retrofit application. MINIMUM CLEARANCE Wall-mount air conditioners are available in both righthand access models and left-hand access models. Right-hand access models have the heat strip access panel, external circuit breakers access panel and internal controls access panel on the right side of the unit. Left-hand access models are a mirror image of the right-hand access models, and allow two wall-mount units to be placed in relatively close proximity and yet still allow complete access for maintenance and repair. On side-by-side installations, maintain a minimum of 26" clearance on control side to allow access to control panel and heat strips, and to allow proper airflow to the outdoor coil. For installations where units are installed with both control panels facing each other (inward), maintain a minimum of 36" clearance to allow access. Additional clearance may be required to meet local or national codes. Care should be taken to ensure that the recirculation and obstruction of condenser discharge air does not occur. Recirculation of condenser discharge air can be from either a single unit or multiple units. Any object such as shrubbery, a building or a large object can cause obstructions to the condenser discharge air. Recirculation or reduced airflow caused by obstructions will result in reduced capacity, possible unit pressure safety lockouts and reduced unit service life. For units with blow through condensers, such as theses wall-mount units, it is recommended there be a minimum distance of 10' between the front of the unit and any barrier or 20' between the fronts of two opposing (facing) units. CLEARANCE TO COMBUSTIBLES Minimum Clearances Required to Combustible Materials SUPPLY AIR DUCT MODELS FIRST 3' All covered by this manual! WARNING Fire hazard. Maintain minimum 1/4" clearance between the supply air duct and combustible materials in the first 3' feet of ducting. Failure to do so could result in fire causing damage, injury or death. The unit itself is suitable for 0" clearance, but the supply air duct flange and the first 3' of supply air duct require a minimum of 1/4" clearance to combustible material. However, it is generally recommended that a 1" clearance is used for ease of installation and maintaining the required clearance to combustible material. See Figure 1.3 on page 12 for details on opening sizes. CABINET 1/4" 0" MODEL IDENTIFICATION Identify the specific model using the model nomenclature information found in Figure 1.1 and/ or model/serial tag found on the unit on the opposite side of the control and access panels. See Figure 1.2 on page 10 for dimensions and critical installation requirements. Clearances Required for Service Access and Adequate Condenser Airflow MODELS LEFT SIDE RIGHT SIDE All covered by this manual 26" 26" Units with control panels 36" between units facing each other (inward) Page 9 of 82

10 Model Width (W) FIGURE 1.2 Dimensions of Basic Unit for Architectural and Installation Requirements (Nominal) Depth (D) Depth Total (DT) Height (H) Supply Return All dimensions are in inches. Dimensional drawings are not to scale. A B C B E F G I J K L M N O P Q R S T W48A/L W60A/L W72A/L W**A RIGHT HAND UNIT W**A LEFT HAND UNIT F F G G F F G G Page 10 of 82 W W Condenser Air Outlet Condenser Air Outlet FRONT VIEW FRONT VIEW W W Condenser Air Outlet Condenser Air Outlet BACK VIEW BACK VIEW HEATER ACCESS PANEL HEATER ACCESS ELECTRIC PANEL HEAT ELECTRIC C. BREAKER/ HEAT DISCONNECT ACCESS C. BREAKER/ PANEL (LOCKABLE) DISCONNECT ACCESS PANEL (LOCKABLE) VENT HOOD 7" DOOR AIR VENTILIATION VENT HOOD 7" DOOR VENTILIATION AIR VENT HOOD LOW VENT VOLTAGE HOOD ELECTRICAL ENTRANCE LOW VOLTAGE ELECTRICAL ENTRANCE HIGH VOLTAGE ELECTRICAL HIGH ENTRANCE VOLTAGE ELECTRICAL ENTRANCE BUILT IN RAIN HOOD 4 BUILT PITCH IN RAIN HOOD PITCH 2.13 VENT HOOD DOOR VENT HOOD VENTILIATION DOOR AIR VENTILIATIONH AIR H J J K K DRAIN DRAIN A A I I C C Cond. Air Cond. Inlet Air Inlet DT DTD D SIDE VIEW SIDE VIEW Cond. Air Cond. Inlet Air Inlet SIDE VIEW SIDE VIEW DT DDT D BUILT RAIN HOOD IN 4 BUILT PITCH IN RAIN HOOD 4 PITCH 2.13 Side Wall 2.13 Mounting Brackets Side Wall (Built Mounting In) Brackets A (Built In) Top Rain A Flashing Top Shipping Rain Flashing I Location Shipping I Location H Optional H Optional Electrical Entrances Electrical C Entrances C K J K J DRAIN DRAIN HEATER ACCESS HEATER PANEL ACCESS ELECTRIC PANELHEAT ELECTRIC C. BREAKER/ HEAT DISCONNECT ACCESS C. BREAKER/ PANEL (LOCKABLE) DISCONNECT ACCESS PANEL (LOCKABLE) 7" 7" VENT HOOD LOW VENT VOLTAGE HOOD ELECTRICAL ENTRANCE LOW VOLTAGE ELECTRICAL ENTRANCE HIGH VOLTAGE ELECTRICAL ENTRANCE HIGH VOLTAGE ELECTRICAL ENTRANCE L L M P M P N N Side Wall Mounting Side Brackets Wall Mounting (Built In) Brackets (Built In) Top Rain Flashing Top Shipping Rain Flashing Location Shipping Location Optional Electrical Optional Entrances Electrical Entrances L M L M P P N N Q Q E OE O SUPPLY AIR OPENING SUPPLY AIR OPENING B B RETURN AIR RETURN OPENING AIR OPENING BOTTOM INSTALLATION BRACKET BOTTOM BACK VIEW INSTALLATION BRACKET BACK VIEW MIS-3618A E OE O SUPPLY AIR OPENING SUPPLY AIR OPENING B B RETURN AIR RETURN OPENING AIR OPENING R R S S S S S S S S S S T T S S S S S S S S S S T T R R Q BOTTOM INSTALLATION Q BACK VIEW BRACKET BOTTOM INSTALLATION BACK VIEWMIS-3618 BRACKET A MIS-3618 A

11 WALL-MOUNT UNIT INSTALLATION MOUNTING THE UNITS! WARNING Heavy item hazard. Use more than one person to handle unit. Failure to do so could result in unit damage or serious injury. NOTE: It may be best to spot some electrical knockouts (such as those located on the back of the wallmount unit) before units are mounted and access is unavailable or limited (see Figure 1.2 to locate prepunched knockouts). Two holes for the supply and return air openings must be cut through the wall as shown in Figure 1.3 on page 12. On wood frame walls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit vibration. Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the installed unit. In retrofit (unit replacement) installations, the openings cut for the original equipment may not line up exactly with needs of this installation. Modifications may need to be made, such as increasing or decreasing the size of the wall cutouts. The existing bolt placement may not line up in which case the original bolts would need to be removed or cut away. 1. These units are secured by wall mounting flanges which secure the unit to the outside wall surface at both sides. A bottom mounting bracket, attached to skid for shipping, is provided for ease of installation, but is not required. 2. The unit itself is suitable for 0" clearance, but the supply air duct flange and the first 3' of supply air duct require a minimum of 1/4" clearance to combustible material. However, it is generally recommended that a 1" clearance is used for ease of installation and maintaining the required clearance to combustible material. See Figure 1.3 for details on opening sizes. 3. Locate and mark lag bolt locations and location for optional bottom mounting bracket, if desired (see Figure 1.3). 4. Mount bottom mounting bracket (if used). 5. If desired, hook top rain flashing (attached to frontright of supply flange for shipping) under back bend of top. 6. Position unit in opening and secure with 5/16" lag/ anchor/carriage bolts; use 7/8" diameter flat washers on the lag bolts. It is recommended that a bead of silicone caulking be placed behind the side mounting flanges. 7. Secure optional rain flashing to wall and caulk across entire length of top (see Figure 1.3). 8. For additional mounting rigidity, the return air and supply air frames or collars can be drilled and screwed or welded to the structural wall itself (depending upon wall construction). Be sure to observe required clearance if combustible wall. 9. A plastic drain hose extends from the drain pan at the top of the unit down to the unit base. There are openings in the unit base for the drain hose to pass through. In the event the drain hose is connected to a drain system of some type, it must be an open or vented type system to assure proper drainage. Page 11 of 82

12 A B C D E REQUIRED DIMENSIONS TO MAINTAIN 1/4" MIN. CLEARANCE FROM COMBUSTIBLE MATERIALS 30 1/2 10 1/2 6 1/4 1 1/4 29 3/4 REQUIRED DIMENSIONS TO MAINTAIN RECOMMENDED 1" CLEARANCE FROM COMBUSTIBLE MATERIALS / D C A C 16" Supply Opening B 16" E 16" Return Opening 16" 16" " 30" 16" 1 1" 3" 4" Typ " 7 8 " " 4" Typ. 2 " " 2 " 3 Wall Opening and Hole Location View FIGURE 1.3 Mounting Instructions SEAL WITH BEAD OF CAULKING ALONG ENTIRE LENGTH OF TOP. TOP WALL PANEL HEATER ACCESS RAIN FLASHING SUPPLIED FOAM AIR SEAL WALL STRUCTURE 1/4" CLEARANCE ON ALL FOUR SIDES OF SUPPLY AIR DUCT IS REQUIRED FROM COMBUSTABLE MATERIALS SUPPLY AIR DUCT RETURN AIR OPENING NOTES: IT IS RECOMMENDED THAT A BEAD OF SILICONE CAULKING BE PLACED BEHIND THE SIDE MOUNTING FLANGES AND UNDER TOP FLASHING AT TIME OF INSTALLATION. Right Side View MIS-3354 Page 12 of 82

13 FIGURE 1.4 Electric Heat Clearance See FIGURE 2 Mounting Instructions FIGURE 1.5 Wall Mounting Instructions FACTORY SUPPLIED RAIN FLASHING. MOUNT ON UNIT BEFORE INSTALLATION WALL STRUCTURE SUPPLY AIR OPENING SUPPLY AIR OPENING SUPPLY AIR DUCT RETURN AIR OPENING RETURN AIR OPENING RETURN AIR OPENING WOOD OR STEEL SIDING BOTTOM MOUNTING BRACKET. MOUNT ON WALL BEFORE INSTALLING UNIT. CONCRETE BLOCK WALL INSTALLATION WOOD FRAME WALL INSTALLATION SIDE VIEW MIS-548 A Page 13 of 82

14 FIGURE 1.6 Wall Mounting Instructions SEE UNIT DIMENSIONS, FIGURE 2, FOR ACTUAL DIMENSIONS. ATTACH TO TOP PLATE OF WALL E B 1.000" CLEARANCE ALL AROUND DUCT INTERIOR FINISHED WALL OVER FRAME 1.000" CLEARANCE ALL AROUND DUCT EXTERIOR FINISH WALL OVER FRAME SUPPLY DUCT OPENING RETURN DUCT OPENING A I C K 2 x 6 CL MIS-549 B FRAMING MATERIAL 2 x 4'S, 2 x 6'S &/OR STRUCTURAL STEEL ATTACH TO BOTTOM PLATE OF WALL THIS STRUCTURAL MEMBER LOCATED TO MATCH STUD SPACING FOR REST OF WALL. A SECOND MEMBER MAY BE REQUIRED FOR SOME WALLS. FIGURE 1.7 Common Wall Mounting Installations SUPPLY DUCT MAY BE LOCATED IN AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN RAIN FLASHING RAFTERS RAIN FLASHING RAFTERS FINISHED CEILING SURFACE SUPPLY AIR DUCT SUPPLY AIR DUCT W/ GRILLE FINISHED CEILING SURFACE RETURN AIR OPENING W/ GRILLE RETURN AIR OPENING W/ GRILLE OUTSIDE WALL OUTSIDE WALL FREE AIR FLOW NO DUCT DUCTED SUPPLY RETURN AT UNIT Page 14 SUPPLY of 82DUCT MAYBE LOCATED IN AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN RAIN SUPPLY DUCT MAYBE LOCATED IN AN ATTIC OR BELOW CEILING RAFTERS AS SHOWN

15 WALL-MOUNT UNIT SUPPLY WIRING All models covered by this installation instruction require VAC utility power to run the compressor, heat, outdoor fan motor, indoor blower and free cooling damper.! WARNING Refer to the unit rating plate or Table 1.1 for wire sizing information and maximum fuse or circuit breaker size. Each outdoor unit is marked with a Minimum Circuit Ampacity. The field wiring used must be sized to carry that amount of current. All models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked Use Copper Conductors Only. These instructions must be adhered to. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes. Electrical shock hazard. Have a properly trained individual perform these tasks. Failure to do so could result in electric shock or death. TABLE 1.1 Electrical Specifications AC POWER CIRCUIT Model Rated Volts, Hertz & Phase Minimum Circuit Ampacity Maximum External Fuse or Circuit Breaker Field Power Wire Size Ground Wire Size W48A2PQ15/W48L2PQ W60A2PQ15/W60L2PQ W72A2PQ15/W72L2PQ These Minimum Circuit Ampacity values are to be used for sizing the field power conductors. Refer to the National Electric Code (latest version), Article 310 for power conductor sizing. CAUTION: When more than one field power circuit is run through one conduit, the conductors must be derated. Pay special attention to note 8 of Table 310 regarding Ampacity Adjustment Factors when more than three (3) current carrying conductors are in a raceway. Maximum size of the time delay fuse or circuit breaker for protection of field wiring conductors. Based on 75 C copper wire. All wiring must conform to the National Electric Code and all local codes. IMPORTANT: While this electrical data is presented as a guide, it is important to electrically connect properly sized fuse and conductor wires in accordance with the National Electrical Code and all local codes. Page 15 of 82

16 The electrical data lists fuse and wire sizes (75 C copper) for all models including the most commonly used heater sizes. Also shown are the number of field power circuits required for the various models with heaters. The unit rating plate lists a Maximum Time Delay Relay Fuse or circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor. Route all field wires to the right of the wire shield as shown in the circuit routing label found in Figure 1.8 (and also on the wall-mount units). Factory Wiring FIGURE 1.9 VAC Supply Wiring Landing Points Field Wiring FIGURE 1.8 Circuit Routing Label ROUTE ALL HIGH VOLTAGE FIELD WIRES TO THE RIGHT OF THE WIRE SHIELD AS SHOWN ACHEMINER LES FILS HAUTE TENSION SUR LA DROITE VERS LA PROTECTION, COMME INDIQUÉ CIRCUIT BREAKER /DISJONCTEUR WIRE SHIELD / PROTECTION NOTE: Right-hand access model wiring landing points are shown here; left-hand access models will mirror this image. IMPORTANT 277/380/575 1-phase and 3-phase equipment use dual primary voltage transformers. All equipment leaves the factory wired on 575V tap. It is very important that the correct voltage tap is used. COMPRESSOR CONTACTOR / CONTACTEUR DU COMPRESSEUR See Figure 1.9 to reference VAC landing points. The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. To convert for the locking capability, bend the tab located in the bottom left-hand corner of the disconnect opening under the disconnect access panel straight out. This tab will now line up with the slot in the door. When shut, a padlock may be placed through the hole in the tab preventing entry. Page 16 of 82

17 FIGURE 1.10 Adjusting the VAC Transformer It is very important that the transformer is wired for the correct 575V voltage 1. Verify incoming AC voltage: Multimeter set to VAC 575VAC + Shelter supply breaker in ON position Bard system breaker in OFF position 575V Three Phase Voltage Range: 546VAC 632VAC 2. Confirm correct wires are connected: For 575V, the gray (575) and black (common) transformer wires must be used. Gray and black wires must be used Page 17 of 82

18 PRELIMINARY START-UP RUNNING IN STAND ALONE (ORPHAN) MODE With the AC breakers turned on, each W-Series wall-mount system has the capability to run without the PLC controller attached this feature is called Stand Alone or Orphan Mode, and it basically keeps the shelter between 60 F and 77 F by the use of the factory-installed return air sensor in each wall-mount unit. During installation, this allows deactivation of one of the two existing, older wall-mount units, while keeping the shelter cool with the other unit still operating. Once the first of the two Bard wall-mount units is installed, Orphan Mode can be enabled early in the installation keeping the climate inside the shelter stable and the installers comfortable while the remainder of the older equipment is removed and the second Bard wall-mount unit and PLC controller is installed. Additionally, should either or both wall-mount units lose communication with the PLC controller (such as during maintenance), they will continue to serve the shelter s needs until a repair can be made. Page 18 of 82

19 BARD-LINK TM CONTROLLER INSTALLATION FIGURE 1.11 Typical LC5000 Wiring RJ11 Cable to Display PLC Board Transformer Web Card Ethernet Cable Connection Power Input 120V, 230V & 240V RS485 Communication Cable Smoke Alarm Jumper Zone 1, 2 & 3 Sensor Shielded Wires Page 19 of 82

20 ! WARNING Electrical shock hazard. Disconnect VAC power supplies before servicing. Failure to do so could result in electric shock or death. LC CONTROLLER The Bard-Link TM LC controller is part of the wall mount Free Cooling Unit system. It is used to control up to 12 wall-mount air conditioners from one controller. The microprocessor control provides an easy-to-read interface with large LCD graphical display. It provides total redundancy for the structure and equal wear on both units. The Bard-Link TM controller is configured for lead/lag/lead/lag sequence. Conduit is recommended for all wiring. Use separate conduits for communication and supply wiring. 1. Mounting the Controller Because the Bard-Link TM controller utilizes a remote temperature sensor as opposed to one located in the controller box, the controller itself can be installed in any indoor location that is suitable, preferably at eye level. Four (4) mounting holes are provided for mounting to the wall and holes for conduit connections are provided in both the base, sides and top of the controller. Single Unit Operation Bard thermostat or can be used in place of the BARD-LINK TM PLC controller when only one W-Series wall mount air conditioner is being installed. If using a thermostat instead of the PLC controller, the alarm logging and remote communication capabilities of the controller will not be available Single Unit Controller, backup real time clock, buzzer and backlit display Single Unit Controller, buzzer and backlit display. For optimum temperature sensor performance, the thermostat should be mounted on an interior wall and away from any heat sources, sunlight, windows, air vents, air circulation obstructions and/or any other cause of erratic or false temperature sensing. Follow the instructions included with or for wiring connections from the thermostat to the wall-mount unit. Page 20 of 82

21 2. Installing Remote Indoor Temperature/Humidity Sensor(s) One remote indoor temperature/humidity sensor is included with the controller. This sensor must be installed for proper operation. Use shielded cable to mount the temperature/humidity sensor in a location least likely to be affected by open doors, rack-mounted fans, radiant heat sources, etc. Locating the sensor between both return grilles is often the best location, but every installation is unique. Location height should be approximately 48" above the floor. The sensor should be installed on a 4" by 4" junction box to allow for control wire conduit (see Figure 1.12). FIGURE 1.12 Remote Indoor Temperature/Humidity Sensor Installation 1. Connect wires from the 18 gauge shielded cable to terminals #6, #7, #17, #18 and # MIS Connect the other end of the shielded cable to the sensor terminals. Be sure wires are connected to proper terminals. Sensor is best mounted on a junction box, and it is recommended that the cable be in conduit. Page 21 of 82

22 For proper operation, the remote indoor temperature/humidity sensor must be configured properly with the controller. If only the single remote indoor temperature/humidity sensor supplied with the controller is installed, the configuration setting is "0". This is the default setting. An additional remote indoor temperature-only sensor can be purchased and installed in Zone 1. Also, temperature and humidity sensors can also be purchased and installed in Zones 2 and 3 (one per zone). For information on remote indoor sensor configuration, see section on additional sensors beginning on page 46. FIGURE 1.13 Additional Remote Temperature and Temperature/Humidity Sensor Installation One additional temperature sensor can be added to Zone 1 and additional temperature/humidity sensors may be added to Zones 2 and 3 (one per zone). Be sure the sensors are connected to the proper terminals as listed below MIS-3730 Zone 1: Optional Remote Temperature Sensor Terminals 8 & 9* TB# Wire Mark Description 8 B2 Indoor Remote Sensor (Zone 1 optional) 9 GND Ground * The two wire connections for the optional remote temperature sensor are not polarity sensitive. Zone 2: Optional Remote Temperature/Humidity Sensor Terminals 10, 11, 20, 21 & 22 TB# Wire Mark Description 10 B3 Indoor Remote Sensor (Zone 2) 11 GND Ground 20 B7 Remote Indoor Humidity Sensor: 0-1 VDC (Zone 2) 21 GND Ground 22 +5V ref Power for B7 Zone 3: Optional Remote Temperature/Humidity Sensor Terminals 12, 13, 14, 15 & 16 TB# Wire Mark Description 12 B4 Indoor Remote Sensor (Zone 3) 13 GND Ground 14 B5 Remote Indoor Humidity Sensor: 0-1 VDC (Zone 3) 15 GND Ground 16 +VDC Power for B5 Page 22 of 82

23 3. Smoke Alarm The LC5000 PLC controller is shipped with smoke detector contacts. There is a factory-installed jumper across terminals #23 and #24. If there is no smoke detector, no action is necessary. If smoke detector alarm is desired, please remove the factory-installed jumper and wire per Figure FIGURE 1.14 Power and Signal Connections for Smoke Detector See Terminal Block Index on page 29 Page 23 of 82

24 4. Communication Wiring Connect the communication wiring from the wall-mount units to the controller in the manner shown in Figure The communication wire should be 2-wire, 18 gauge shielded cable with drain. Any color can be used. Be sure to match "+" and "-" symbols on controller terminal blocks to prewired unit control terminal block (see Figures 1.17 and 1.18 on pages 26 and 27). Attach communication wire filters as shown in Figure Use separate conduits for communication and supply wiring. FIGURE 1.15 Communication Wiring Wall-Mount Unit Wall-Mount Unit Bard-Link TM Controller Page 24 of 82

25 FIGURE 1.16 Communication Wiring: Termination at the Controller 1. Using the field-provided shielded cable, make a small service loop after entering the controller and attach the provided EMI filter at the intersection of the loop. 2. Connect one wire to terminal #27 (negative), the other wire to terminal #28 (positive) and the drain wire to ground terminal # MIS-3730 To Wall-Mount Unit 1 Control Board RS485 Page 25 of 82

26 FIGURE 1.17 Communication Wiring: Termination at the First Wall-Mount Unit RS485 PLAN R+T+ / R-T- Wall-Mount Unit 1 Control Board From LC Controller 0 1. From the controller, extend the shielded cable through a separate conduit and route to the provided terminal block next to the wall-mount control board. Note that the terminal block label is clearly marked + and -. These connections are polarity-sensitive. Two-wire communication from control board is prewired to terminal block. Make sure to match "+" and "-" symbols on controller terminal blocks. Wall-Mount Unit 1 Control Board RS485 PLAN R+T+ / R-T- 2. Connect the wires matching the terminal designations (+/-) of the controller terminals. Leave the drain wire loose. From LC Controller Wall-Mount Unit 1 Control Board RS485 PLAN R+T+ / R-T- 3. Connect another cable in a similar fashion ( daisy chain ) to route in conduit to the second wall-mount unit. Connect both drain wires with wire nut. From LC Controller To Wall-Mount Unit 2 Control Board RS485 Page 26 of 82

27 FIGURE 1.18 Communication Wiring: Termination at Additional Wall-Mount Units RS485 PLAN R+T+ / R-T- Wall-Mount Units 2 24 Control Board 1. Route the cable from the first wall-mount unit to the terminal block of the second wall-mount unit. Make a small service loop and attach EMI filter as shown. From Wall-Mount Unit 1 RS485 Wall-Mount Units 2 24 Control Board RS485 PLAN R+T+ / R-T- 2. Connect the wires matching the terminal designations (+/-) of the controller terminals. Cap the loose drain with a wire nut or electrical tape. From Wall-Mount Unit 1 RS485 Page 27 of 82

28 6. Supply Wiring The LC controller is powered by 120/208/230 from the shelter. Field-supplied supply wiring should be minimum 16 guage, maximum 14 guage (see Figure 1.19). A reliable earth ground must be connected in addition to any grounding from conduit. Grounding posts are included with the controller for this purpose; install as shown in Figure Failing to ground the controller box properly could result in damage to the equipment. FIGURE 1.19 Bard-Link TM LC Controller Circuit Install See Terminal Block Index on following page. FIGURE 1.20 Controller Grounding Posts A reliable earth ground must be connected in addition to any grounding from conduit. Attach earth ground to dedicated lugs on side of controller box. Failing to ground the controller box properly could result in damage to the equipment. Page 28 of 82

29 TB# Wire Mark VAC Input VAC Input VAC Input TABLE 1.2 Terminal Block Index 4 Power Input Common 5 Power Input Ground Description 6 B1 Indoor Remote Sensor (Zone 1) 7 GND Ground 8 B2 Indoor Remote Sensor (Zone 1 optional) 9 GND Ground 10 B3 Indoor Remote Sensor (Zone 2) 11 GND Ground 12 B4 Indoor Remote Sensor (Zone 3) 13 GND Ground 14 B5 Remote Indoor Humidity Sensor: 0-1 VDC (Zone 3) 15 GND Ground 16 +VDC Power for B5 17 B6 Remote Indoor Humidity Sensor: 0-1 VDC (Zone 1) 18 GND Ground 19 +5V ref Power for B6 20 B7 Remote Indoor Humidity Sensor: 0-1 VDC (Zone 2) 21 GND Ground 22 +5V ref Power for B7 23 D11 Smoke Detector Alarm 24 D1C1 Common for DI1 D17 25 FBR- RS4585 RX-/TX- 26 FBR+ RS4585 RX+/TX+ 27 PLR- PLAN RX-/TX- 28 PLR+ PLAN RX+/TX+ 29 GND COMMS GROUND Page 29 of 82

30 DATE 1:1 SCALE SD CHECKED 6/5/2015 CAL DRAWN BY CY APPROVED Bard Mfg. Co. Bryan, Ohio DISTRIBUTION FIGURE 1.21 LC5000 Wiring Diagram 110V IN 208V IN 230V IN COMMON IN GND JMP GND BLACK RED ORANGE WHITE RED B1 GREEN RED B2 GREEN RED B3 GREEN RED B4 GREEN RED B5 GREEN BLK/RED +VDC RED B6 GREEN YELLOW RED B7 GREEN GND YELLOW +5 VREF BLUE/BLK DI1 BLK/WHITE DIC1 BLACK FIELDBUS RX/TX - BLACK FIELDBUS RX/TX+ BLACK PLAN RX/TX - BLACK PLAN RX/TX+ TB 22 TB 6 TB 8 TB 10 TB 12 TB 14 TB 17 TB 20 TB 21 TB 16 TB 23 TB 24 G G0 +VDC GND +5 VREF B1 B2 B3 B4 B5 B6 B7 GND +VDC D11 D12 D13 D14 D15 D16 D17 DIC1 GND Y1 Y2 Y3 BLUE YELLOW RX-TX- RX+TX+ GND VOUT RX-TX- RX+TX+ GND C1 N01 N02 N03 C2 N04 N05 N06 N07 C3 NC7 TB 27 TB 28 TB 25 TB TB Wire # Mark Description VAC Input VAC Input VAC Input 4 POWER INPUT COMMON 5 POWER INPUT GROUND 6 B1 Indoor Remote Sensor (Zone 1) 7 GND GND 8 B2 Indoor Remote Sensor (Zone 1 - Optional) 9 GND GND 10 B3 Indoor Remote Sensor (Zone 2) 11 GND GND 12 B4 Indoor Remote Sensor (Zone 3) 13 GND GND 14 B5 Remote Indoor Humidity Sensor: 0-1Vdc (Zone 3) 15 GND GND 16 +VDC Pow er for B5 17 B6 Remote Indoor Humidity sensor: 0-1Vdc (Zone 1) 18 GND GND 19 +5Vref Pow er for B6 20 B7 Remote Indoor Humidity sensor: 0-1Vdc (Zone 2) 21 GND GND 22 +5Vref Pow er for B7 23 DI1 Smoke Detector Alarm 24 DIC1 Common for DI1 - D17 25 FBR- RS485 RX- / TX- 26 FBR+ RS485 RX+ / TX+ 27 PLR- PLAN RX- / TX- 28 PLR+ plan RX+ / TX+ 29 GND COMMS GROUND Page 30 of 82

31 SYSTEM START-UP The Bard-Link TM controller and TEC-EYE handheld diagnostic tool will both be used to set up the controller and wall-mount units (see Figure 1.24 on page 32). The TEC-EYE diagnostic tool is shipped inside the controller. 1. Set Controller Date and Time 1) Shut down all breakers to wall-mount units and the Bard-Link TM controller. 2) Restore AC power to the wall-mount units. 3) Turn on power to the Bard-Link TM controller. There is a forty (40) second delay prior to any function (other than display backlight) becoming active. The Status screen is the default screen when the controller has power. 4) Access the controller Main Menu by pressing the Menu key. 5) Press the UP or DOWN keys to scroll to the Clock/Scheduler menu. Press the ENTER key (see Figure 1.22). 6) Move the cursor to the Date line by pressing the ENTER key. Press the UP or DOWN keys to change the date. The Day line will automatically change when the date has been altered. 7) Press the ENTER key to move to the Hour line. Press the UP or DOWN keys to change the time. Press the ENTER key to set the time. 8) Press the ESCAPE several times to return to the Status menu. FIGURE 1.22 Clock/Scheduler Menu 2. Enter Total Units 1) On LC controller, go to Technician menu and press ENTER key. 2) Go to Unit Set Up menu, press ENTER key. 3) Press ENTER key to move cursor to Total Units. Use the UP arrow key to change unit count to the number of units that will be connected to the LC controller (see Figure 1.23). FIGURE 1.23 Total Units Displayed 3. Set Up and Configure Units Set up and configuration must be done to each unit using the TEC-EYE hand-held diagnostic tool. 1) Remove communication wire connection plug from wall unit control board (see page 39). 2) On the TEC-EYE, go to Technician menu, press ENTER key. 3) Go to Unit Set Up menu, press ENTER key. 4) Use the ENTER key to select the zone number (1, 2 or 3) the unit will be utilized in to condition the space. Press ENTER key. 5) Select mode of operation for the unit. The options are Active, Standby, Active Locked and Standby Locked. Active: When mode is set to Active, the unit will be available to cool the space. Standby: When mode is set to Standby, the unit is available for rotation or if an alarm is activated on an Active mode unit. Active Locked: When mode is set to Active Locked, the unit is not available for rotation Standby Locked: When mode is set to Standby Locked, the unit is not available for rotation but is available to come on if an alarm is activated on Active mode units. 6) Set unit address: This address must be unique for each unit to be recognized on the network. Set the address to 1-12 and press the ENTER key. 7) Set cool stage option: Options are 1 for units with a single stage compressor (comes on 100% when call for mechanical cooling) or 2 for units with a two stage compressor (comes on at part load initially and increases to 100% capacity). Select and set for 1 or 2 and press ENTER key. Page 31 of 82

32 8) Set heat stage option: Options are 1, 2 or 3. When value is set to 1, this enables single stage. (6KW only) When value is set to 2, it enables stage 1 or stage 2. (6KW or 9KW) When value is set to 3, enables stage 3 stages to satisfy space. EXAMPLE: For total 15KW heat (6 + 9 KW heat strips) Stage 1 6KW ON Stage 2 6KW OFF, 9KW ON Stage 3 9KW ON, 6KW ON (stage 3 is through software to bring stage 1 back on to total 15KW) Stage 1 Stage 2 Stage 3 6KW ON OFF ON 9KW OFF ON ON 9) Reattach communication wire connection plug to wall unit control board that was removed in Step 1. After first unit has been set up and configured, follow the above steps to set up and configure the rest of the wall units. FIGURE 1.24 Bard-Link TM Controller and TEC-EYE ALARM KEY MENU KEY ESCAPE KEY UP KEY ENTER KEY DOWN KEY ALARM KEY UP KEY MENU KEY ENTER KEY ESCAPE KEY DOWN KEY ALARM KEY Allows viewing of active alarms Silences audible alarms Resets active alarms MENU KEY Allows entry to Main Menu ESCAPE KEY Returns to previous menu level Cancels a changed entry UP KEY Steps to next screen in the display menu Changes (increases) the value of a modifiable field ENTER KEY Accepts current value of a modifiable field Advances cursor DOWN KEY Steps back to previous screen in the display menu Changes (decreases) the value of a modifiable field Page 32 of 82

33 4. Verify Communication to Units Check controller display to see that all units are "online". This typically takes 3-4 minutes after controller is powered. If all units are online, the display will appear as shown in Figure If any of the units are not online, the display will appear as shown in Figure FIGURE 1.25 Status Display Showing Units "Online" To determine which unit or units are offline: 1) Press MENU button to go to main menu. 2) Go to Board Switch menu, press ENTER. Display will show which unit or units are offline (see Figure 1.27). Units offline will show up as "no device connected". In Figure 1.27, Unit 3 is not showing up as online. 3) Check the wiring connections on the units showing as offline. 4) Repeat Steps 1-3 to confirm unit online status and further diagnose connection issues if necessary. FIGURE 1.27 Board Switch Display FIGURE 1.26 Status Display Showing Units "Offline" Units Unit 3 not showing as online LC LC and TEC-EYE Displays Board Switch Display Icons Controllers (I/O Boards) active in network Display(s) active in network No device connected 5. Run Test Units Using the TEC-EYE, a run test should be executed on each unit to verify the equipment is functioning correctly. 1) On the TEC-EYE, go to Technician menu, press ENTER key. 2) Press UP or DOWN arrow keys to get to Service Settings menu, press ENTER key. 3) Press UP or DOWN arrow keys to get to Control Setting menu, press ENTER key. 4) Cursor will be flashing in upper left corner of screen. Press DOWN arrow key to scroll through screens to Run Test. Page 33 of 82

34 5) Press ENTER key to scroll to Enable. Press UP or DOWN arrow keys to change No to Yes. Unit will begin the run test (see Figure 1.28). FIGURE 1.28 Executing Run Test TABLE 1.3 Controller Default Settings Description Temperature at local remote (main) sensor Default Setpoint Temperature Setpoint 77 F -- Heating Setpoint 60 F Temperature High Limit Level 1 Temperature High Limit Level 2 (High Temp Alarm) 85 F 90 F Temperature Low Limit 45 F Run Test Approximate Timings (in Minutes) Blower On: 0:00 Damper Open: 0:00 2:40 Closed: 2:41 4:57 Compressor On: 4:58 Off: 6:00 Heat On: 6:01 Off: 7:10 Blower Off: 8:19 6. Complete Installation Once all the installation steps have been completed, and system verification and run test results were satisfactory, the installation can now be considered complete. The Bard-Link TM PLC lead/lag controller has been pre-programmed with what is widely considered to be the most efficient operating parameters see Table 1.3. Further information on exact sequence of operation and advanced programming changes can be found in the Service Instructions section of this manual. WEB CARD COMMUNICATION BOARD NOTE: A web card communications board allows remote access, via Ethernet, to all functions of the controller system. This is the same as if one was in the building where the controller system is physically installed. Connect the Bard-Link TM LC controller Ethernet port to the existing Ethernet card in the shelter (if applicable) using CAT 6 Ethernet cable. Cooling Stage Differential 1 F Minimum Compressor Run Time Minimum Compressor Off Time 3 Minutes 2 Minutes Comfort Mode Setpoint 72 F Comfort Mode Operation Time 60 Minutes DC Freecooling Setpoint 55 F Lead/Lag Changeover Time (Rotation) Temperature Units F 1 Page 34 of 82

35 SECTION 2: SERVICE INSTRUCTIONS Page 35 of 82

36 GENERAL REFRIGERANT INFORMATION These units require R-410A refrigerant and polyol ester oil. GENERAL 1. Use separate service equipment to avoid cross contamination of oil and refrigerants. 2. Use recovery equipment rated for R-410A refrigerant. 3. Use manifold gauges rated for R-410A (800 psi/250 psi low). 4. R-410A is a binary blend of HFC-32 and HFC R-410A is nearly azeotropic similar to R-22 and R-12. Although nearly azeotropic, charge with liquid refrigerant. 6. R-410A operates at 40-70% higher pressure than R-22, and systems designed for R-22 cannot withstand this higher pressure. 7. R-410A has an ozone depletion potential of zero, but must be reclaimed due to its global warming potential. 8. R-410A compressors use polyol ester oil. 9. Polyol ester oil is hygroscopic; it will rapidly absorb moisture and strongly hold this moisture in the oil. 10. A liquid line dryer must be used even a deep vacuum will not separate moisture from the oil. 11. Limit atmospheric exposure to 15 minutes. 12. If compressor removal is necessary, always plug compressor immediately after removal. Purge with small amount of nitrogen when inserting plugs. TOPPING OFF SYSTEM CHARGE If a leak has occurred in the system, Bard Manufacturing recommends reclaiming, evacuating (see criteria above) and charging to the nameplate charge. If done correctly, topping off the system charge can be done without problems. With R-410A, there are no significant changes in the refrigerant composition during multiple leaks and recharges. R-410A refrigerant is close to being an azeotropic blend (it behaves like a pure compound or single component refrigerant). The remaining refrigerant charge in the system may be used after leaks have occurred. Top-off the charge by utilizing the pressure charts on the inner control panel cover as a guideline. REMEMBER: When adding R-410A refrigerant, it must come out of the charging cylinder/tank as a liquid to avoid any fractionation and to insure optimal system performance. Refer to instructions for the cylinder that is being utilized for proper method of liquid extraction. SAFETY PRACTICES 1. Never mix R-410A with other refrigerants. 2. Use gloves and safety glasses. Polyol ester oils can be irritating to the skin, and liquid refrigerant will freeze the skin. 3. Never use air and R-410A to leak check; the mixture may become flammable. 4. Do not inhale R-410A the vapor attacks the nervous system, creating dizziness, loss of coordination and slurred speech. Cardiac irregularities, unconsciousness and ultimately death can result from breathing this concentration. 5. Do not burn R-410A. This decomposition produces hazardous vapors. Evacuate the area if exposed. 6. Use only cylinders rated DOT4BA/4BW Never fill cylinders over 80% of total capacity. 8. Store cylinders in a cool area, out of direct sunlight. 9. Never heat cylinders above 125 F. 10. Never trap liquid R-410A in manifold sets, gauge lines or cylinders. R-410A expands significantly at warmer temperatures. Once a cylinder or line is full of liquid, any further rise in temperature will cause it to burst. R410-A REFRIGERANT CHARGE This unit was charged at the factory with the quantity of refrigerant listed on the serial plate. AHRI capacity and efficiency ratings were determined by testing with this refrigerant charge quantity. The pressure table found on the following page shows nominal pressures for the units. Since many installation specific situations can affect the pressure readings, this information should only be used by certified technicians as a guide for evaluating proper system performance. They shall not be used to adjust charge. If charge is in doubt, reclaim, evacuate and recharge the unit to the serial plate charge. Page 36 of 82

37 TABLE 2.1 Nominal Pressures: Models W48, W60, W72 Air Temperature Entering Outdoor Coil, Degree F Model Return Air Temperature Pressure W48 W60 W72 75 DB 62 WB 80 DB 67 WB 85 DB 72 WB 75 DB 62 WB 80 DB 67 WB 85 DB 72 WB 75 DB 62 WB 80 DB 67 WB 85 DB 72 WB Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side Pressure ±4 PSIG High Side Pressure ±10PSIG FIGURE 2.1 Refrigerant Sight Glass The refrigerant sight glass installed in this unit is not a charging indicator. Use only universally recommended practices of charging: superheat, subcooling,and preferably, weighing in the correct charge. The sight glass is for moisture reference only. Page 37 of 82

38 SEQUENCE OF OPERATION WALL-MOUNT UNIT SEQUENCE OF OPERATION Overview This product is designed to function like a typical Telecom air conditioning system with an outdoor air-cooling damper. However, the FCU system does have some special features, like a PLC control which allows for advanced alarming and a DC Free Cooling feature that allows for forced emergency ventilated cooling anytime shore power VAC power from the utility company is lost. The internal controls within this unit automatically recognize a loss of shore power, energizing the indoor blower motor and powering the actuator to open the damper to bring in outdoor air. The power utilized during this time is the stored battery power from the equipment shelter. Indoor Blower The indoor blower is an AC voltage motor. For the blower to activate, this action must take place: 24VAC from terminal N07 (Blower Motor Start Relay) Free Cooling Damper This controller is enabled for dewpoint control, specifically examining the combination of temperature and relative humidity to determine the proper control of cooling. This calculated dewpoint property then determines the proper mode of cooling Outdoor Air, Mechanical Cooling, or both. To signal the 24VAC damper actuator to open, a 2-10VDC signal must come from the Y2 terminal. Cooling Call When a call for cooling generates from the controller, the system will first determine which mode of cooling to employ based on the outdoor temperature, the outdoor humidity, and the indoor temperature. If the outdoor temperature and humidity ratio are conducive to free cooling, the control board will send: VDC Signal from Y2 (Damper Signal) - Modulates damper to achieve 55 F at supply air temperature sensor 2. 24VAC from terminal N07 (Blower Motor Start Relay) If the outdoor conditions are conducive to free cooling, but a 2nd stage cooling call is generated, the board will additionally add 24VAC signal from the N02 terminal to the CCM, activating the compressor. The damper will limit outdoor air to keep supply air temperature at 55 F. If conditions outside are not conducive to free cooling, the control board will send: 1. 24VAC signal from N02 to CCM (Compressor) 2. 24VAC from terminal N07 (Blower Motor Start Relay) VDC signal from Y1 (Speed Voltage) Heating Call When a call for heating generates from the controller, the control board will send: 1. 24VAC signal from terminal N04 to heat strip contactor VAC signal from terminal N05 to heat strip contactor 2. Loss of Utility Power VDC Signal from terminal Y2 (Damper Signal) - Modulates damper to achieve 55 F at supply air temperature sensor 2. 24VAC from terminal N07 (Blower Motor Start Relay) Special Considerations High Pressure Situation The high pressure switch routes through the compressor control module (CCM), which allows one switch opening followed by a delay (soft lockout) of at least 2 minutes before trying again. If the switch is still open or opens again on the same call the CCM locks out the compressor and outdoor fan. Additionally, the CCM will send 24V to the high pressure alarm relay, which will then send a digital input to the DI 3 terminal. Low Pressure Situation The low pressure switch is routed directly to DI 4 on the board and has a very specfic scheme of operation: 1. If the switch opens, the board ignores the switch for 2 minutes (OAT above 50 F) or 3 minutes (OAT below 50 F). 2. If the switch is still open after the delay, the board will stop compressor and outdoor fan function (soft lockout) for 2 minutes. Page 38 of 82

39 3. If after 2 minutes, the low pressure switch is still open, or opens again immediately aftward, the board will delay for 2 minutes again (soft lockout). 4. On the 3rd attempt, the board will lock out the compressor and outdoor fan until manually reset. High Temperature 2 Alarm Should the shelter controller see 90 F, both free-cooling dampers will open (regardless of outdoor temperature) to cool the building. Smoke Alarm Should the smoke detector send an alarm signal to the controller, all blower, compressor and ventilations functions cease. Freezestat If coil temperature below 30 F is sensed by the freezestat, the compressor will deactivate for 5 minutes, or until the sensor sees 55 F, whichever comes first. FIGURE 2.2 Wall-Mount Unit Control Board Dirty Filter Switch High Pressure Alarm Relay Low Pressure Switch Air Proving Switch Damper Blade Switch Common Common/Control Ground 2-10VDC Free-Cooling Damper Signal 24V to OA Humidity Sensor Ground Freezestat Sensor 10kΩ Outdoor Air Humidity Sensor 4-20mA Return Air Temp Sensor 10kΩ Outdoor Air Temp Sensor 10kΩ Mixed Air Temp Sensor 10kΩ +24VAC from Transformer 24VAC from Transformer 24VAC from Transformer 24VAC Output to Motor Start Relay 24VAC Heating Stg2 Output to Limit Switch 24VAC Heating Stg1 Output to Limit Switch +24VAC Power Input +24VAC Power Input Communication Wire + Communication Wire 24VAC Cooling Output to Compressor Control Module Page 39 of 82

40 LC SERIES PLC CONTROLLER SEQUENCE OF OPERATION Overview The LC Series PLC controller is designed to operate up to 12 Bard wall-mount units in a lead/lag fashion, while offering extensive alarming capabilities as well as remote communication. The duty of the PLC controller is to monitor temperature and alarm conditions within the shelter and to send cooling or heating orders to one, or more, wall-mount units. The controller also monitors the units and sends alarms. Inputs/Outputs The LC controller will make decisions and trigger alarms by the use of inputs and outputs to various field-installed connections to the terminal block. Please refer to the Installation section of this manual for further information on field-wire connections. Power Inputs: 120 VAC, 208 VAC or 230 VAC power to terminals 1 (+) and 2 (-). This feeds the VAC to 24VAC power, which then powers the board. NOTE: Output must be minimum 21.6 VAC to allow proper PLC board operation. Power Outputs: 24VAC power to hydrogen detector through terminals 3 (+) and 4 (-). The + terminal block is fused internally (see Componentry section). 24VDC power to smoke detector through terminals 6 (+) and 7 (-). The + terminal block is fused internally (see Componentry section). -24VDC power to generator run relay contacts (if available) on terminal 9. Signal Inputs: 10K ohm remote indoor temperature sensor on terminals 11 and K ohm optional remote indoor temperature sensor on terminals 13 and K ohm optional remote indoor temperature sensor on terminals 15 and 16. Communication Output: Negative (-) communication wire to terminal 27. Positive (+) communication wire to terminal 28. Cable drain wire to terminal 29. Isolation Relays and Alarm Schemes Low Temp: If 45 F is sensed in the shelter, the LC board will send -24VAC to the low temp relay to energize the relay, opening contacts on terminals 27 and 28. Additionally, the board will send remote alarms. High Temp: If 90 F is sensed in the shelter, the LC board will send -24VAC to the high temp relay to energize the relay, opening contacts on terminals 25 and 26. Additionally, the LC will send remote alarms and enable blowers and free cooling dampers in an attempt to cool the shelter. Page 40 of 82

41 FIGURE 2.3 LC-5000 Controller Control Board and Terminal Block LC-5000 Control Board Terminal Block FIGURE 2.4 LC-5000 Controller Control Board MIS-3730 Smoke Detector Common for Smoke Detector 24V to Outdoor Air Humidity Sensor Ground Remote Indoor Humidity Sensor Zone 2 Remote Indoor Humidity Sensor Zone 1 Remote Indoor Humidity Sensor Zone 3 Remote Temp Sensor Zone 3 Remote Temp Sensor Zone 2 Optional Remote Temp Sensor Zone 1 Remote Temp Sensor Zone 1 +24VDC from Transformer 24VDC from Transformer LC-5000 Control Board Communication Wire + Communication Wire Humidifier Communication Wire (if equipped) + Humidifier Communication Wire (if equipped) Page 41 of 82

42 FIGURE 2.5 Free Cooling Damper Operation Free cooling can take place providing the outside air meets three (3) separate criteria: 1. The dewpoint must be below 60 F 2. The relative humidity must be below 80% 3. The outside air must be cooler than the current setpoint. With an accurate psychrometer, it is easy to pinpoint when the damper should be open or closed during normal operations. Below 80% Relative Humidity Below 60 F Dewpoint TABLE 2.2 Controller Default Settings Description Temperature at local remote (main) sensor Default Setpoint -- Temperature Setpoint 77 F Heating Setpoint 60 F Temperature High Limit Level 1 Temperature High Limit Level 2 (High Temp Alarm) 85 F 90 F Temperature Low Limit 45 F Cooling Stage Differential 5 F Heating Stage Differential 2 F Comfort Mode Setpoint 72 F Comfort Mode Operation Time 60 Minutes Freecooling Setpoint 55 F Lead/Lag Changeover Time (Active/Standby Rotation) Temperature Units F 1 Page 42 of 82

43 ADVANCED PROGRAMMING FIGURE 2.6 Bard-Link TM Controller Display ALARM KEY MENU KEY ESCAPE KEY UP KEY ENTER KEY DOWN KEY ALARM KEY Allows viewing of active alarms Silences audible alarms Resets active alarms MENU KEY Allows entry to Main Menu ESCAPE KEY Returns to previous menu level Cancels a changed entry UP KEY Steps to next screen in the display menu Changes (increases) the value of a modifiable field ENTER KEY Accepts current value of a modifiable field Advances cursor DOWN KEY Steps back to previous screen in the display menu Changes (decreases) the value of a modifiable field BARD LINK TM CONTROLLER USER INTERFACE The microprocessor control used in these wall mount air conditioners allows for complete control and monitoring through the use of the Bard Link TM LC controller. These controllers utilize the latest in state-of-the-art technology including a large, easy-toread backlit LCD graphic display. The menu driven interface provides users the ability to scroll through three menu levels: Info, Control and Service. The menus permit the user to easily view, control and configure the unit. The controller is completely programmed at the factory; therefore, most applications will require no field set-up. However, the default setpoints and their ranges are easily viewed and adjusted from the controller display. The program and operating parameters are permanently stored on FLASH-MEMORY in case of power failure. The controller is designed to manage temperature levels to a user-defined setpoint via control output signals to the wall-mount air conditioning system. WEB CARD COMMUNICATION BOARD A web card communications board allows remote access, via Ethernet, to all functions of the controller system. This is the same as if one was in the building where the controller system is physically installed. CONTROLLER POWER-UP Whenever power is first applied to the controller, there is a forty (40) second time delay prior to any function (other than display) becoming active. CONTROLLER INTERFACE ACRONYMS MAT Mixed air temperature RAT Return air temperature OAT Outdoor air temperature OAH Outdoor air humidity Zone 1 Space temperature and humidity Zone 2 If sensor connected Zone 3 If sensor connected Blower Indoor Blower Status Damper Free cooling damper position status C1 Compressor activate status H1 Heater Stage 1 status H2 Heater Stage 2 status ODP Calculated outdoor dew point FC Free cooling status RN Component run time in minutes in last hour ST Number of start requests in last hour Page 43 of 82

44 CONTROLLER INTERFACE MENU STRUCTURE On/Off Unit Setpoints Clock/Scheduler Input/Output Analog Inputs Digital Inputs Relay Outputs Analog Outputs Alarm History Board Switch Technician Information BMS Configuration Service Settings I/O Configuration Probe Adjustment Control Setting* History Reset Manual Managment Analog Inputs Digital Inputs Relay Outputs Analog Outputs Factory Configuration I/O Configuration Factory Settings Initilization In addition to the menu structure above, there are also Status and Alarm screens. Press the MENU key from any screen to return to the Main Menu. Press the UP or DOWN keys to scroll through the available menus. When the desired menu is highlighted, press the ENTER key to access that menu. Press the ESCAPE key or MENU key to return to the STATUS screen from the Main Menu. Comfort Mode 1. Press and release the ENTER key for comfort mode to change the Cooling Setpoint to 72 F for a period of 1 hour. 2. Setpoints will return to the programmed settings automatically after 1 hour. 3. The status screen will display COMFORT MODE while in overide mode. 4. Pressing the ENTER key during the 1-hour period will deactivate COMFORT MODE. Status Screen The STATUS screen is the default start-up screen and also the return screen after 5 minutes of no activity. The screen can be accessed any time by pressing the ESCAPE button repeatedly. * Option to enable humidifier The main screen of the STATUS screen displays the current date, time, zone temperature and humidity. Using the UP/DOWN arrow keys, the user can scroll through a host of other information: SAT/RAT/OAT/OAH and ODP at unit(s) connected to network Last hour averages information Last hour tracking information FIGURE 2.7 Controller Status Display For the following items, press the MENU key to access programming. Entering Total Units 1. Go to Technician menu and press ENTER key. 2. Go to Unit Set Up menu, press ENTER key. 3. Press ENTER key to move cursor to Total Units. Use the UP arrow key to change unit count to the number of units that will be connected to the LC controller (see Figure 2.8). FIGURE 2.8 Total Units Displayed Verifying Communication to Units Check controller display to see that all units are "online". If all units are online, the display will appear as shown in Figure 2.9. If any of the units are not online, the display will appear as shown in Figure To determine which unit or units are offline: Page 44 of 82

45 1. Press MENU button to go to main menu. 2. Go to Board Switch menu, press ENTER. Display will show which unit or units are offline (see Figure 2.11). Units offline will show up as "no device connected". In the example below, Unit 3 is not showing up as online. 3. Check the wiring connections on the units showing as offline. 4. Repeat Steps 1-3 to confirm unit online status and further diagnose connection issues if necessary. FIGURE 2.9 Status Display Showing Units "Online" Run Test Execute a run test on each unit to verify the equipment is functioning correctly. 1. Go to Technician menu, press ENTER key. 2. Press UP or DOWN arrow keys to get to Service Settings menu, press ENTER key. 3. Press UP or DOWN arrow keys to get to Control Setting menu, press ENTER key. 4. Cursor will be flashing in upper left corner of screen. Press ENTER key to scroll to Run Test. 5. Press UP arrow key to change "No" on screen to "Yes". Will begin the run test (see Figure 2.12). FIGURE 2.12 Executing Run Test FIGURE 2.10 Status Display Showing Units "Offline" Run Test Approximate Timings (in Minutes) Blower On: 0:00 Damper Open: 0:00 2:40 Closed: 2:41 4:57 Compressor On: 4:58 Off: 6:00 Heat On: 6:01 Off: 7:10 Blower Off: 8:19 FIGURE 2.11 Board Switch Display* Board Switch Display Icons Controllers (I/O Boards) active in network Units Display(s) active in network No device connected LC and TEC-EYE Displays Unit 3 not showing as online LC * This same display can also be viewed on the TEC-EYE Page 45 of 82

46 Adjusting Date and Time 1. Go to Clock/Scheduler menu, press ENTER key. 2. Move the cursor to the selected choice by pressing the ENTER key. 3. Press UP or DOWN arrow keys to change the date and/or time. The day will automatically change when the date has been altered. Setting Continuous Blower 1. Go to Setpoint menu, press ENTER key. 2. Go to Blower Settings screen, move the cursor to the selected choice by pressing the ENTER key. 3. Press UP or DOWN arrow keys to change the desired value: Active: Active unit blower only All: Active and standby units continuous Advancing Lead/Lag (Active/Standby) Positions 1. Go to Clock/Scheduler menu, press ENTER key. 2. Go to Unit Rotation screen. 3. To switch lead unit: Move the cursor to the selected choice by pressing the ENTER key. Press UP or DOWN arrow keys to change the desired value. Unit rotation will change from Active to Standby. Changing to Celsius 1. Go to Technician menu, press ENTER key. 2. Press UP or DOWN arrow keys to get to Service Settings menu, press ENTER key. 3. Press UP or DOWN arrow keys to get to Control Setting menu, press ENTER key. 4. Move the cursor to Temperature Unit by pressing the ENTER key. Press UP or DOWN arrow keys to change to C. This will be a global change within the units on the structure; the temperature value will be displayed in C for all locations within the display. Calibrating Sensors 1. Go to Technician menu, press ENTER key. 2. Go to Service Settings menu, press ENTER key. 3. Go to Probe Adjustment, press ENTER key. 4. Move the cursor to enter the offset to the temperature value. Example: The sensor reading displays on the screen as 80 F and the actual measured value using a calibrated sensor is 77 F. Enter an offset of -3.0 F to display the temperature correctly. An offset of -9.9 F to +9.9 F can be entered. Resetting Controller Model/Serial Numbers 1. Go to Factory menu, press ENTER key. 2. Go to Factory Settings screen, press ENTER key. 3. Press the ENTER key to move the cursor to the Serial Number selection. Press and hold UP or DOWN arrow keys to get to the desired value and then press ENTER key. Repeat for the rest of the digits/characters: Press and hold UP or DOWN arrow keys to get to the desired value and then press ENTER key to key in next digits/characters. 4. Model number is entered by the factory. In the case it is accidently changed, the field technicians will need to enter the model number. Follow Step 3 above to enter the model number in the same fashion that the serial number was entered. Enabling Humidifier 1. Go to Technician menu, press ENTER key. 2. Go to Service Settings menu, press ENTER key. 3. Go to Control Setting, press ENTER key. 4. Press ENTER key to move the cursor to Humidifier. Press UP or DOWN arrow keys to make the desired selection. Z1-1 Zone 1, Qty. 1 Humidifier Z1-2 Zone 1, Qty. 2 Humidifier Z1-3 Zone 1, Qty. 3 Humidifier or Z1 & Z2 Zones 1 and 2, Qty. 1 per Zone Humidifier or Z1 & Z2 & Z3 Zones 1, 2 and 3, Qty. 1 per Zone Humidifier High voltage power to humidifier(s) external by others! Configuring Additional Remote Zone 1 Temperature Sensor 1. Go to Technician menu, press ENTER key. 2. Go to Service Settings menu, press ENTER key. 3. Go to I/O Configuration, press ENTER key. 4. Go to Analog Inputs, press ENTER key. 5. To enable an additional Zone 1 temperature sensor, move cursor to desired zone by pressing the ENTER key. Go to Remote Zone 1. Press ENTER key to change EN: OFF to ON, Ch: BOO2. Configuring Additional Zone Remote Temperature and Humidity Sensors 1. Go to Technician menu, press ENTER key. 2. Go to Service Settings menu, press ENTER key. 3. Go to I/O Configuration, press ENTER key. Page 46 of 82

47 4. Go to Analog Inputs, press ENTER key. 5. To enable Zone 2 and Zone 3 temperature sensors, move cursor to desired zone by pressing the ENTER key: Zone 2: Go to Remote Zone 2. Press ENTER key to change EN: OFF to ON, Ch: BOO3. Zone 3: Go to Remote Zone 3. Press ENTER key to change EN: OFF to ON, Ch: B To enable Zone 2 and Zone 3 humidity sensors, move cursor to desired zone by pressing the ENTER key: Zone 2: Go to Humidity Zone 2. Press ENTER key to change EN: OFF to ON, Ch: BOO7. Zone 3: Go to Humidity Zone 3. Press ENTER key to change EN: OFF to ON, Ch: B005. Acknowledging/Clearing Alarms Alarm conditions activate a red LED indicator that backlights the ALARM function key. As an option, an alarm condition may also be enunciated by an audible alarm signal. An alarm is acknowledged by pressing the ALARM key. This calls up alarm display screen(s) that provide a text message detailing the alarm condition(s). After an alarm condition is corrected, the alarm can be cleared by pressing the ALARM key. Simulating Smoke Alarm 1. Go to Technician menu, press ENTER key. 2. Go to Manual Management, press ENTER key. 3. Go to Digital Inputs, press ENTER key. 4. Press the ENTER key to move the cursor to Smoke Manual DI 1 and press ENTER key. 5. Press UP or DOWN arrow keys to change the value from "Open" to "Closed"; alarm activates. 6. Reverse procedure to terminate test. TABLE 2.3 Controller Programmable Features and Default Settings Description Range Default Setpoint Units Temperature at local remote (main) sensor Temperature Setpoint F Heating Setpoint F Temperature High Limit - Level F Temperature High Limit - Level F Temperature Low Limit F Cooling Stage Differential F Heating Stage Differential F Comfort Mode Setpoint F Comfort Mode Operation Time Minutes Freecooling Setpoint F Lead-Lag Changeover Time (Rotation) 1-30 days, or 0 for disabled 1 Day(s) Temperature Units F/ C F -- CAUTION The Bard 575 volt wall mount unit system has been pre-programmed with what is widely considered to be the best settings for efficiency and operation. Any changes to internal programming through the LC-Series Controller or the TEC-EYE not covered within this manual may cause the systems to operate improperly, cause internal damage to the HVAC units, cause the shelter to overheat, or other very serious consequences. Although complete controller programming architecture for both the LC-Controller and TEC-EYE has been provided, going outside the boundaries of what has been covered in this manual is not recommended. Page 47 of 82

48 USING THE TEC-EYE FIGURE 2.13 TEC-EYE Display ALARM KEY UP KEY MENU KEY ENTER KEY ESCAPE KEY DOWN KEY ALARM KEY Allows viewing of active alarms Silences audible alarms Resets active alarms MENU KEY Allows entry to Main Menu ESCAPE KEY Returns to previous menu level Cancels a changed entry UP KEY Steps to next screen in the display menu Changes (increases) the value of a modifiable field ENTER KEY Accepts current value of a modifiable field Advances cursor DOWN KEY Steps back to previous screen in the display menu Changes (decreases) the value of a modifiable field TEC-EYE HAND-HELD DIAGNOSTIC TOOL The microprocessor control used in this wall mount air conditioning system allows for complete control and monitoring through the use of the provided TEC- EYE hand-held monitor. This comprehensive service tool utilizes the latest in state-of-the-art technology including a large, easy-to-read backlit LCD graphic display. The menu driven interface provides users the ability to scroll through three menu levels: Info, Control and Service. The menus permit the user to easily view, control and configure the unit. The controller is completely programmed at the factory; therefore, most applications will require no field set-up. However, the default setpoints and their ranges are easily viewed and adjusted from the TEC-EYE display. The program and operating parameters are permanently stored on FLASH-MEMORY in case of power failure. The controller is designed to manage temperature levels to a user-defined setpoint via control output signals to the wall mount air conditioning system. The TEC-EYE connects to the wall-mount unit control board via an RJ11 modular phone connector as shown in Figure The TEC-EYE hand-held diagnostic tool should be stored inside the Bard-Link TM PLC controller. FIGURE 2.14 TEC-EYE Connection to Unit Control Modular Phone Connector for TEC-EYE Hand-Held Diagnostic Tool Page 48 of 82

49 TEC-EYE Menu Structure On/Off Unit Setpoints Clock/Scheduler Input/Output Analog Inputs Digital Inputs Relay Outputs Analog Outputs Alarm History Board Switch Technician Information Working Hours Service Settings I/O Configuration Probe Adjustment Control Setting History Reset Manual Management Analog Inputs Digital Inputs Relay Outputs Analog Outputs Factory Configuration I/O Configuration Factory Settings In addition to the menu structure above, there are also Status and Alarm screens. TEC-EYE Acronyms MAT Mixed air temperature RAT Return air temperature OAT Outdoor air temperature OAH Outdoor air humidity Zone 1 Space temperature and humidity Zone 2 If sensor connected Zone 3 If sensor connected Blower Indoor Blower Status Damper Free cooling damper position status C1 Compressor activate status H1 Heater Stage 1 status H2 Heater Stage 2 status ODP Calculated outdoor dew point FC Free cooling status RN Component run time in minutes in last hour ST Number of start requests in last hour Press the MENU key to access the Main Menu screen. Press the UP or DOWN keys to scroll through the available menus. When the desired menu is highlighted, press the ENTER key to access that menu. Press the ESCAPE key or MENU key to return to the STATUS screen from the Main Menu. Status Screen The STATUS screen is the default start-up screen and also the return screen after 5 minutes of no activity. The screen can be accessed any time by pressing the ESCAPE button repeatedly. The STATUS screen displays the current date, time, return air temperature, supply air temperature, outdoor air temperature, outdoor humidity and outdoor dewpoint conditions. FIGURE 2.15 TEC-EYE Status Display For the following items, press the MENU key to access programming. Setpoints: Local Cool and Heat/Current Cool and Heat If at any time the unit(s) loses communication with the LC controller, the unit(s) will go to stand alone or orphan mode. During this time, the user has the option to change local cool and heat setpoints so that the unit(s) maintain the new setpoint value. On power cycle, the local cool and heat will revert back to the current cool and heat setpoint values (which are driven by the LC controller). To change local and cool and heat setpoints (applicable only when in stand alone (orphan mode): 1. Go to Setpoints menu, press ENTER key. 2. Press DOWN arrow key to get to desired screen. 3. Move the cursor to the selected choice by pressing the ENTER key. Press UP or DOWN arrow keys to change Local Cool and/or Local Heat value. FIGURE 2.16 Local Cool/Heat and Current Cool/Heat Setpoints Page 49 of 82

50 Executing a Run Test Execute a run test on each unit to verify the equipment is functioning correctly. 1. Go to Technician menu, press ENTER key. 2. Press UP or DOWN arrow keys to get to Service Settings menu, press ENTER key. 3. Press UP or DOWN arrow keys to get to Control Setting menu, press ENTER key. 4. Cursor will be flashing in upper left corner of screen. Press DOWN arrow key to scroll through screens to Run Test. 5. Press ENTER key to scroll to Enable. Press UP or DOWN arrow keys to change No to Yes. Unit will begin the run test (see Figure 2.17). FIGURE 2.17 Executing Run Test Run Test Approximate Timings (in Minutes) Blower On: 0:00 Damper Open: 0:00 2:40 Closed: 2:41 4:57 Compressor On: 4:58 Off: 6:00 Heat On: 6:01 Off: 7:10 Blower Off: 8:19 Identifying a Unit Address 1. Go to On/Off Unit menu. 2. Screen will display individual address of wallmount unit. Manual Override Outputs Blower 1. Go to Technician menu, press ENTER key. 2. Go to Manual Management, press ENTER key. 3. Go to Relay Outputs, press the DOWN arrow to get to Blower Relay Output. Move the cursor to the selected choice by pressing the ENTER key. Press UP or DOWN arrow keys to change the Manual Relay and Manual Position to ON. 4. Press ESCAPE key. Free Cooling Damper 1. Go to Technician menu, press ENTER key. 2. Go to Manual Management, press ENTER key. 3. Go to Analog Outputs, press ENTER key. 4. Press DOWN arrow key to scroll screens to Analog Output 2 Damper. 5. Press ENTER key to scroll to Mode line. Press DOWN key to change Auto to Hand. 6. Press ENTER key to scroll to Manual Value line; Press UP or DOWN arrow keys to change the manual value to a desired value (maximum is 10VDC) to perform damper test. 7. Verify damper operation. Page 50 of 82

51 Compressor 1. Go to Technician menu, press ENTER key. 2. Go to Manual Management, press ENTER key. 3. Go to Relay Output, press ENTER key. 4. Go to Relay Output Cooling Stage. Press UP or DOWN arrow keys to change Manual Relay to ON ; press ENTER key. Press UP or DOWN arrow keys to change manual position to ON and press ENTER key. 5. Verify compressor is running. Heat 1. Go to Technician menu, press ENTER key. 2. Go to Manual Management, press ENTER key. 3. Go to Relay Output, press ENTER key. 4. Go to Relay Output Heating, press ENTER key. 5. Press UP or DOWN arrow keys to change Manual Relay and Manual Position to ON and press ENTER key. 6. Verify heater ON status. 7. Repeat Steps 1-6 to enable Stage 2 heat. (Before enabling Stage 2 heater, make sure the Stage 2 heater option is enabled under Unit Set-Up.) CAUTION The Bard 575 volt wall mount unit system has been pre-programmed with what is widely considered to be the best settings for efficiency and operation. Any changes to internal programming through the LC-Series Controller or the TEC-EYE not covered within this manual may cause the systems to operate improperly, cause internal damage to the HVAC units, cause the shelter to overheat, or other very serious consequences. Although complete controller programming architecture for both the LC-Controller and TEC-EYE has been provided, going outside the boundaries of what has been covered in this manual is not recommended. Page 51 of 82

52 COMPONENTRY SPECIFICATIONS! WARNING Electrical shock hazard. Disconnect VAC power supply before servicing. Failure to do so could result in electric shock or death. LOW PRESSURE SWITCH Cut-out pressure: 40psi (+/- 4 psi) Cut-in pressure: 55psi (+/- 4psi) HIGH PRESSURE SWITCH Cut-out pressure: 650psi (+/- 10 psi) Cut-in pressure: 520psi (+/- 15psi) LOW AMBIENT CONTROL Modulating head-pressure control that allows full speed at pressures above 315psi. Below 315psi, the control will slow fan speed following internal head pressures until a minimum RPM is reached (approx 300 RPM). Below this point, the control will shut the fan completely off until internal pressures rise. The control is preset from the factory, but should adjustment become necessary, there is an adjustment screw located on the bottom of the control behind a weatherproof cap. One full turn clockwise equals approximately +48 psi. REMOTE INDOOR TEMPERATURE SENSOR White, decorative plastic casing, Bard logo, fieldinstalled in shelter: 10k ohm resistance, see Table 2.4. MIXED AIR TEMP SENSOR 4.75 stainless probe factory mounted in supply opening of wall-mount unit: 10k ohm resistance, see Table 2.4. RETURN TEMPERATURE SENSOR Exposed thermistor-element style with copper-coated steel clip, attached in return opening of wall-mount unit: 10k ohm resistance, see Table 2.4. EVAPORATOR TEMP SENSOR (FREEZESTAT) Exposed thermistor-element style with copper-coated steel clip, attached to evaporator coil of wall-mount unit: 10k ohm resistance, see Table 2.4. OUTDOOR TEMPERATURE/HUMIDITY SENSOR Gray, weather-proof octagonal case with dip tube, located in condenser section of wall-mount unit. Temperature sensor: 10k ohm resistance, see Table 2.4. Humidity sensor: 4-20mA. COMPRESSOR CONTROL MODULE Compressor protection device that has an adjustable 30-second to 5-minute timer (red-dial). This module features a delay-on make for initial start-up (or anytime power is interrupted) for a minum 2 minutes plus 10% of the red-dial setting. There is no delay during routine operation of the unit. The compressor control module (CCM) also monitors the high pressure switch, and will allow one automatic retry (after soft lockout delay) before disabling the compressor in a hard lockout (requires manual reset). If hard lockout does occur, the ALR terminal on the CCM will become active with 24V, which will power the high pressure relay within the wallmount unit, breaking a digital input to the PLC control signaling a high-pressure situation to the system. PHASE MONITOR Used only on 3-phase equipment, the phase monitor is a compressor protection device that will prohibit operation of the compressor if the device senses a possible reverse-rotation situation due to incorrect phasing. On a call for compressor (and only compressor), the device will check incoming phase, check for severe voltage imbalance and check for proper frequency. Under nominal conditions, a green LED light will show on the face of the monitor. If there is improper phasing, voltage imbalance or frequency deviation, the device will show a red LED light and prohibit compressor operation. TRANSFORMER 100VA with external 5A circuit breaker, 575VAC convertible. Directly feeds low voltage in wall-mount unit during normal operation. FUSED TERMINAL BLOCKS Black, hinged DIN-rail mount terminal block with an internal glass tube fuse, used in the LC-Series controller for 24VAC power supply to both hydrogen and smoke alarms: Phoenix UK5-HESI AIRFLOW SWITCH Located inside the blower compartment, this switch measures air pressure proving and will send out an alarm on motor lockout (see Figure 2.19 on page 54). Manual reset only. Default setting: 0.8" static. Page 52 of 82

53 TABLE 2.4 Temperature (F) vs. Resistance (R) of Temperature Sensor F R F R F R F R COMPRESSOR CRANKCASE HEATER Units are equipped with crankcase heaters that are rated for the connnected voltage and operate during compressor off cycle. DIRTY FILTER SWITCH Located inside the blower compartment, this switch measures air pressure differential across the filter (see Figure 2.19 on page 54). Manual reset only. Default setting: 0.8"static, 50% blocked filter (approximately). ZETTLER ISOLATION RELAYS: WALL-MOUNT UNIT Black Zettler surface mount relays used in the wallmount unit to isolate the start signal from the high pressure relay circuit (see Figure 2.20 on page 54). FUSES 5x20mm time delay, glass tube fuse: 250VAC rated voltage, 35 rated amp interruption at rated voltage. BATTERIES Used in wall-mount unit and controller boards, flat-disk style BR2330 3V battery. Used only for time/date during complete power loss. Estimated lifespan 7-8 years. Page 53 of 82

54 FUSE BLOCK 2-pole DIN-rail mount finger safe fuse block rated for 600VAC. OUTDOOR FAN MOTOR Due to design considerations of the condenser section of the wall-mount unit, placement/clearance of the motor/fan blade is critical to heat dispersal. Should a change of motor or fan blade be necessary, please view Figure 2.18 for proper clearance adjustment. INDOOR BLOWER MOTOR Unlike most other system fan motors, this motor is very specialized in application.see Table 2.5 (blower table). MODEL TABLE 2.5 Indoor Blower Performance RATED ESP MAX ESP FREE COOLING RATED FULL LOAD COOLING CFM ELECTRIC HEAT AIRFLOW AIRFLOW FIGURE 2.18 Fan Blade Setting MIS-1724 Model All covered by this manual Dimension A 1.75" "A" FIGURE 2.19 Dirty Filter Switch and Airflow Switch (Two Switches) W48A/W48L W60A/W60L W72A/W72L Free Cooling Logic Control derives at this decision point and switches the indoor motor speed. The damper actuator will then adjust to still yield a 55 F supply air temperature. On single-stage models, this only occurs when using a thermostat/controller with "Y2" cooling stage connected. FIGURE 2.20 High Pressure Relay Circuit Page 54 of 82